System and method for top loading of items into receptacles

ABSTRACT

A system for loading a plurality of items in series into a receptacle held in an item holding device, comprises a plurality of item holding devices each adapted for holding an item receptacle adapted to hold a plurality of items. A holding devices moving apparatus such as a conveyor, moves the plurality of item holding devices through an item loading station with the item receptacles being oriented at a first angle to the horozinal. An item delivery apparatus delivers a plurality of items separately in series at an item orientation that is at a second angle to the item receptacles. The item delivery apparatus may include a metering device comprising a wheel member having a plurality of generally radially extending, generally equally spaced finger members, with all adjacent finger members being configured at a distance there between proximate end portions of said adjacent finger members. The radial position of the fingers, and thus the distance between end portions, is adjustable.

FIELD OF THE INVENTION

The present invention relates to a system and method for top loading ofitems into receptacles including holding devices. The invention may beemployed for loading blister pack items, which may contain consumablessuch as batteries into receptacles. The receptacles may for example betrays with slots for holding a plurality of blister packs.

BACKGROUND

There are known systems for the top loading of several items intoproduct containers or receptacles. Some of these systems employconveyors, where products to be loaded are transferred from a productconveyor into containers carried by a container conveyor. While in somesystems, products can be transferred laterally from a product conveyorinto a container carried by a container conveyor, for many products andproduct containers it is desirable or necessary to instead top load theproducts into the containers.

While there are known systems and methods for top loading products,including multiple products, into a series of containers/receptacles,they suffer from drawbacks.

One particular application that is problematic is the loading aplurality of blister packaged items into receptacles. Some blister packshave a lower edge portion that must be received into a correspondingtransverse slot in the receptacle. The receptacles can be configured toprovide a display stand that a retailer can use to display the items forsale in a store or the like.

In view of the foregoing an improved method and system for top loadingof items into holding devices is desired.

SUMMARY OF THE INVENTION

According to one aspect of the invention there is provided a system forloading a plurality of items in series into a receptacle held in an itemholding device, comprising a plurality of item holding devices eachadapted for holding an item receptacle adapted to receive and hold aplurality of items; a holding device moving apparatus for moving theplurality of item holding devices to and through an item loading stationwith the item receptacles being oriented at a first angle to thehorizontal; an item delivery apparatus delivering to an item loadingstation, a plurality of items separately in series at an itemorientation that is at a second angle to the item receptacles when eachreceptacle is at the item loading station, the item delivery apparatusdirecting items towards each receptacle in turn held in a holding deviceat the item orientation; wherein each item of the plurality of items isdelivered in series by the item delivery apparatus towards eachreceptacle held in a holding device, and each holding device is movedthrough the item loading station to permit a plurality of items to beloaded into each the receptacle.

According to another aspect of the invention there is provided a systemfor delivering a plurality of items comprising an input apparatus, awheel member and an output apparatus, the wheel member having aplurality of generally radially extending, generally equally spaced,finger members, with all adjacent finger members being configured at adistance there between proximate end portions of the adjacent fingermembers, for holding at least one item there between.

According to another aspect of the invention there is provided a systemfor loading a plurality of items in series into an item holding device,comprising: a plurality of item holding devices each adapted for holdingan item receptacle adapted to receive and hold at least one item; aholding device moving apparatus for moving the plurality of item holdingdevices to and through an item loading station with the itemreceptacles; an item delivery apparatus delivering a plurality of itemsto the item loading station, the item delivery apparatus directing itemstowards the item holding device; an energy absorption member, positionedto be impacted by the items discharged toward the item holding devicepositioned at the item loading station; wherein each item is deliveredby the item delivery apparatus toward the holding device in such amanner that it impacts the energy absorption member which assists inloading the receptacle with the item.

According to another aspect of the invention there is provided a systemfor loading a plurality of items in series into an item holding device,comprising: a plurality of item holding devices each adapted for holdingan item receptacle adapted to receive and hold at least one item; aholding device moving apparatus for moving the plurality of item holdingdevices to and through an item loading station with the itemreceptacles; an item delivery apparatus delivering a plurality of itemsin series to the item loading station, the item delivery apparatusdirecting items towards an item holding device located at the loadingstation; a resilient spring member, the spring member movable from (a) aresting position to (b) a displaced position when impacted by an itemdischarged by the item delivery apparatus toward the item holding deviceto (c) a item loading position wherein the spring moves the item to aposition where it can be more readily be received by the item holdingdevice; wherein each item is delivered by the item delivery apparatustoward the holding device in such a manner that it impacts the springmember which assists in loading the receptacle with the item.

According to another aspect of the invention there is provided a methodfor loading a plurality of items in series into an item holding device,comprising: moving a plurality of item holding devices each adapted forholding an item receptacle adapted to receive and hold a plurality ofitems thorough an item loading station with intermittent movement, theitem receptacle being oriented at a first angle to the horizontal;delivering a plurality of items separately in series at an itemorientation that is at a second angle to the item receptacles at theitem loading station; wherein each item of the plurality of items isdelivered in series by the item delivery apparatus into the receptacleat the orientation, and the holding device is moved through the itemloading station to permit the plurality of items to be loaded into theitem holding device.

BRIEF DESCRIPTION OF THE DRAWINGS

In Figures which illustrate by way of example only, embodiments of thepresent invention:

FIG. 1 is a plan view of a system in accordance with an exampleembodiment of the present invention;

FIGS. 2 and 2 a are schematic side elevation view of part of system ofFIG. 1;

FIG. 2 b is a schematic plan view in direction 2 b shown in FIG. 2 a;

FIG. 3 is a side elevation view of part of the system of FIG. 1, similarto the views of FIGS. 2 and 2 a;

FIG. 4 is an enlarged view of portion of FIG. 3, designated as 4 therein

FIG. 4 a is a view similar to FIG. 4, but illustrating in solid linesthe components of the item reject system in an item non-reject position;

FIG. 4 b is a view similar to FIG. 4 a, but illustrating in solid linesthe components of the item reject system in an item reject position;

FIG. 5 is an enlarged view of portion of FIG. 1, designated as 5therein;

FIG. 6 is another enlarged view, similar to FIG. 4, but of a largerportion of FIG. 3;

FIG. 7 is a schematic, side perspective view of a receptacle held by apuck device being loaded with a battery pack, employed in the system ofFIG. 1;

FIG. 8 a is a schematic, top perspective view of a puck device holding areceptacle loaded with several battery packs, that can be employed inthe system of FIG. 1;

FIG. 8 b is a top view of the puck device of FIG. 8 a;

FIG. 8 c is a side elevation view of the puck device of FIG. 8 a;

FIGS. 9 a and 9 b are schematic side elevation views, similar to FIG. 7,showing the loading of a battery pack into a receptacle held in a puckdevice;

FIG. 10 is a front perspective view of a battery pack metering device inisolation, and which forms part of the system of FIG. 1;

FIG. 11 is a rear perspective view of the metering device of FIG. 10;

FIG. 12 a is a side front elevation view of the metering device of FIG.10, showing certain interior components thereof, in shadow outline, withfingers in a fully extended position;

FIG. 12 b is a similar view to FIG. 12 a, but showing the fingers in afully retracted position;

FIG. 13 a is a rear exploded perspective view of the metering device ofFIG. 10;

FIG. 13 b is a rear exploded perspective view of the metering device ofFIG. 10;

FIG. 14 a is a front elevation view of another part of the system ofFIG. 1;

FIG. 14 b is a bottom perspective view of the part of FIG. 14 a, forclarity shown with only one item receptacle dispenser mechanism;

FIGS. 15 a and 15 b are front elevation and side elevation viewsrespectively of the part of FIGS. 14 a and 14 b, shown in the first ofthree sequential operational positions;

FIGS. 16 a and 16 b are front elevation and side elevation viewsrespectively of the part of FIG. 14, shown in the second of threesequential operational positions;

FIGS. 17 a and 17 b are front elevation and side elevation viewsrespectively of the part of FIG. 14, shown in the third of threesequential positions;

FIGS. 18 a and 18 b are perspective views of an item receptacleplacement checking mechanism in both operational and non-operationalpositions; and

FIG. 19 is perspective view of a puck holding device that can beemployed in embodiments of the invention.

DETAILED DESCRIPTION

As shown in FIG. 1, a system 11 for the top loading of items 20 intoholding devices containing item receptacles 22 comprises two sub-systems10 a, 10 b, each including several components. Items 20 may be numerousdifferent types of items. However, the present system 11 describedherein is particularly configured for loading so-called blister packagescontaining a plurality of batteries in a blister type plastic andcardboard package, as shown in detail FIG. 7. Items 20 have a blisterportion 20 a which can be a plastic material, often transparent orsemi-transparent, that holds a plurality of batteries or some otherproduct to a cardboard backing portion. The item 20 can also have anupper section 20 c and a lower portion 20 b. The lower portion 20 b isconfigured to fit into a slot 22 a of a receptacle 22. The receptacle 22can be formed with a corrugated upper surface contour with slots 22 aformed thereon. Surrounding the perimeter of the receptacle 22 is a lip22 e (see FIG. 7). Receptacle 22 can be made from a material such as aplastic like a thermoplastic polyurethane elastomer and slots 22 a canbe configured such that they are resiliently displaced when a lowerportion 20 b of an item 20 is received therein. In this way, the items20 can be held upright in the receptacle 22. Receptacle loaded with aplurality of items 20 can be used for display purposes in a retailenvironment. However, in other embodiments, other item holding devices22 could be employed, such as some types of trays, cartons or othercontainers.

The sub-systems 10 a and 10 b can, as shown in FIG. 1, be generallyarranged in side by side relationship, and each is independentlycapable, on a continuous basis, of top loading a plurality of items 20into successive item receptacles held in a plurality of item holdingdevices 28. The operation of both sub-systems 10 a, 10 b can becontrolled by a common Programmable Logic Controller (PLC) 32. PLC 32may be an Allen Bradley model SLC 504 controller.

Each sub-system 10 a, 10 b includes an item holding device conveyor, 12a, 12 b, and a corresponding item delivery conveyor 14 a, 14 b. Itemholding device conveyor 12 a functions with item delivery deviceconveyor 14 a, in the same way as item holding device conveyor 12 bfunctions with item delivery conveyor 14 b, as described hereafter.System 10 employs two sub-systems 10 a and 10 b to increase the itemloading capacity of system 11. Only one such sub-system could beemployed, or more than two could be employed depending upon theparticular operational requirements. Hereinafter, only one of thesub-systems (hereinafter referred to generically as sub-system 10) isdescribed with reference to an item holding device conveyor 12, an itemdelivery conveyor 14 and other components.

As shown in FIGS. 1 and 2, a sub-system 10 includes item holding deviceconveyor 12 and item delivery conveyor 14 are mounted to a framegenerally designated 15. The system can also include an item unloadingdevice 34 (FIG. 1) which can be a robot device such as a FANUC modelM420i with a robot arm having an end effector configured to pick upitems 20 being held in holding devices 28 carried on the item holdingdevice conveyor 12. It should be noted that in the illustrated system, asingle robot device 34 can be provided which is capable of unloadingitem holding devices loaded with items 20, from both conveyor 12 a andconveyor 12 b.

Item holding device conveyor 12 consists of an endless, upward facingconveyor belt 36 which can be driven continuously around a conveyor path13. Sub-system 10 also includes a plurality of item holding devices 28,which can be, as will be described later, a plurality of puck devices28. Pucks 28 are generally carried around the conveyor path 13 by theconveyor belt 36. As will be evident from FIG. 1, in plan view thegeneral shape of the conveyor path 13 is rectangular, and has curvedportions at its corners. Belt 36 can be formed as a flexible conveyorbelt, which enables belt 36 to negotiate the corners of the generallyrectangular path 13. The conveyor path 13 does not, however, have to begenerally rectangular in shape, in plan view. The conveyor 12 cangenerally be formed on an aluminum-extruded beam construction, with lowfriction slide rails guiding a plastic multi-flexing belt 36. Flexiblelink conveyor systems suitable for deployment as conveyor system 12include the Flex Link conveyors made by SKF or FlexLink AB.

Belt 36 has an upper surface that co-operates with the underneath/lowersurface 41(f) of base portions 41 (See FIG. 8 b) of pucks 28, to providesufficient frictional engagement between the belt and the base 41 of thepuck members 28. The puck members 28 then sit freely on top of belt 36.Due to the frictional engagement between belt and puck 28, the pucks 28move along the generally horizontal portions of the conveyor path 13driven by the belt 36. The belt 36 is supported in part, and guided byhorizontally disposed idler wheels 38, which in the illustratedembodiment are disposed at each of the four corners, of the generallyrectangular conveyor path 13. The idler wheels 38 have an upward facingsurface, which frictionally engages the underside of belt 36 and so willrotate with the movement of belt 36. The Belt 36 has a cross sectionshaped like a horizontal H so idler wheels 38 fit in between the tophorizontal and the bottom horizontal portion. The belt 36 is drivenaround the conveyor path by a conveyor drive 39 (see FIG. 3), which canalso be provided as part of the conveyor system package provided by asupplier such as SKF or FlexLink AB.

As puck members 28 are driven in series around the conveyor path by belt36, they will be guided along this path by a series of upstanding guiderails 30, which can also be formed from extruded aluminum and whichengage the side surfaces 41(c) of the bases 41 of the pucks 28.

The conveyor path 13 followed by each of the pucks 28 can be can beconsidered to commence at a generally upwardly sloped ramp portion 13(i)followed by a generally horizontal upper section 13(ii), which in turnleads to an item receptacle loading station 13(iii) portion. After theitem receptacle loading station 13(iii) the puck move along the conveyorpath to a downwardly sloped ramp portion 13(iv) that includes an itemloading station 17 (FIG. 2). After moving from the downward ramp portion13(iv) the pucks 28 travel along a generally horizontal lower section13(v) to an item unloading station 13(vi). After item unloading station,the pucks then move again to upwardly sloped ramp portion 13(i) andrepeat thereafter repeat the path.

Some further features of the movement of pucks 28 by belt 36 are asfollows. During the upwardly sloped ramp portion 13(i) of the conveyorpath 13, the frictional engagement of the upper side of belt 36 againstthe underside of puck 28, may not be sufficient to ensure reliablemovement up the upwardly sloped ramp. Therefore, to assist in themovement of pucks 28 up ramp portion 13(i), as shown in FIG. 1, anadditional lug conveyor (designated 23) can be disposed adjacent to itemholding device conveyor 12 in the region of ramp portion 13(i). Lugs 21carried by a conveyor belt on this lug conveyor 23 can engage a part ofeach puck 28 (e.g. such as a rear face 41(b) (See FIG. 8 b) and also bedriven at approximately the same speed (or faster) as item holdingdevice conveyor 12 to help push the pucks 28 up the ramp portion 13(i).

Conveyor 23 can use a Flexlink belt and a conveyor drive, such as forexample is also manufactured by SKF or FlexLink AB, and which is similarto the conveyor 12. However, conveyor 23 is provided with upstandingspaced lugs 21 for engaging a rear portion of a rear face of pucks 28.It should be noted that lug conveyor 23 could be disposed between thebelts 36 of both sub-systems 10 and 10 b, and be configured and employedto assist in moving pucks 28 up adjacent conveyor belts 36 of sub-system10 a and sub-system 10 b.

At item receptacle loading station 13(iii), the movement of pucks 28 isdelayed for a period of time, sufficient to allow an item receptacle 22to be loaded into each puck by an item receptacle dispenser 16 (see FIG.2). A location device 50 controlled by system PLC 32 can be employed tohold successive puck or pucks 28 in place for a limited period of time,in an item receptacle loading position. An example of such a locationdevice 50 is illustrated in FIG. 19. Device 50 has a frame 802 to whichis mounted a pneumatic cylinder 803 having a vertically orientedreciprocating piston arm 809 to which is affixed a lifting pad 804. Alsosecured to frame 802 is a pneumatic cylinder 808 having a transverselyoriented, reciprocating piston arm 810. A vertically oriented plate 807is affixed to the end of piston arm 810. Plate 807 has affixed at anupper end, a wedge member 806 having a longitudinally extending v-shapedwedge portion. Also integrated with the longitudinally extending wedge,is a v-shaped, vertically extending oriented, ridge portion that is alsoconfigured in a vertical v-shape. The operation of the piston arm 810 issuch that the ridges of wedge member 806 engage corresponding grooves inpuck 28, as illustrated in FIGS. 8 a-8 c. When a puck 28 arrives at astation, the puck is first stopped by an extended blocking arm 37.Thereafter, first cylinder 803 lifts the puck 28 vertically away fromthe belt 36 with lifting pad 804. After that, cylinder 808 pushes lowerpotion of the plate 807 so that v-grooved wedge 806 engages with thegrooves formed in the side of the puck 28 and presses the opposite sideof the puck 28 against support bar 805. The reverse procedure can becarried out in order to release the puck 28. The location device 50 ismounted on the frame of the belt conveyor by simply attaching locatingframe 802 to it. The operation of arm 37 and locating device 50 iscontrolled PLC 32.

The type of device such as is sold by SKF or FlexLink AB under modelXMPX150A can readily be adapted and employed in this system as alocation device 50.

With reference to FIGS. 8 a-8 c, a puck 28 is shown which comprises abase portion 41, from which extends upwards, a plurality of upstandingarm members 40 a-c. Front arms 40 a extend upwards proximate a leadingfront edge face 41 a of base 41 and have an end portion which extends inan angled forward direction. Rear arms 40 b extend upwards proximate atrailing rear edge face 41 b of base 41 and have a lower portion 40 b(i)which is substantially perpendicular to base surface 41 e; a medialportion 41 b(ii) which extends at an angle in a rearward directionrelative to the lower portion. Finally rear arms 40 b have an upper endportion 41 b(iii) which extends at a larger angle in a rearwarddirection relative to the medial portion 41 b(ii). Oppositely disposedpairs of side arms 40 c and 40 d, extend upwards proximate side edgesfaces 41 c and 41 d respectively of base 41, and each have an endportion which extends in an angle transversely outward. The upperportions of arms 40 a to 40 d guide an item receptacle 22 received fromthe item receptacle dispenser 16 onto upper surface 41 e of puck 28, toa desired flat orientation on the upper surface 41 e of base 41. Thelower portions of all arms 40 a-40 d maintain the receptacles in properlongitudinal and transverse orientation during their journey alongconveyor path 13 from loading to unloading stations.

It will also be observed that pucks 28 have integrally formed down oneside surface 41 d, a continuous gear tooth mesh 52. As will describedhereinafter, gear mesh 52 engages the teeth of a rotating drive gearwheel 43 (See FIG. 5) during movement of puck 28 along part of conveyorpath 13. Gear wheel 54 can be driven by a servo drive motor controlledby PLC 32. Although not necessary, an additional gear tooth mesh andcorresponding gear drive wheel could also be provided along oppositeside surface 41 c. Alternatively, other types of known intermittentmovement drive mechanisms could be used, such as belt driven systemswhich may for example, employ a servo-motor drive, to move the pucksthrough item loading station 17 with the desired motion (FIG. 2). Itwill be appreciated that in many embodiments, it will be necessary thatthe pucks 28 move through the item loading station 17 with intermittentmovement.

Side face 41 c of base 41 of puck 28 is provided with a verticallyorientated groove 45 that is configured in a longitudinal v-shape. Thisgroove co-operates with the vertical v-shaped wedge portion on themember 806 of the locating and holding device 50 referenced above. Theinsertion of the vertical v-shaped wedge into groove 45 will provide forlongitudinal alignment of the puck along the conveyor path, so thelongitudinal position of the puck is known. Side face 41 c is alsoprovided with a longitudinally oriented groove 46 that is configured ina vertical v-shape, and the longitudinally extending wedge of member 806will be located in this groove to enhance the holding of the puck 28.

Side face 41 c also has ID markers 44 and 43, which can be detected by avision or proximity sensing device which are positioned adjacent certainlocations along conveyor path 13. The proximity sensing devices arecapable of recognizing the presence of, or movement past, of an IDmarker 43 or 44, and then send a signal to PLC 32. In this way PLC 32 isnotified by a signal of when a puck is in a particular position alongthe path. The ID markers 43/44 can in some embodiments be simply a steelbolt screwed into the side surface of the puck 28 or other visualmarker.

By way of example, one or more proximity sensing devices 48 (See FIG. 2)may be located proximate item receptacle loading station 13(iii) onconveyor path 13. A suitable sensing device that could be employed isthe model 872C-D5NP 18-D4 made by Allen-Bradley. Proximity sensingdevice 48 can detect if and when ID markers 43/44 are in the properposition to activate the holding device 50. As mentioned above,pneumatically activated blocking member 37 (see FIG. 3) controlled byPLC 32, can also be provided in the vicinity of station 13(iii). When inan extended upright position, blocking member 37 will hold a puck 28 inan item receptacle receiving position. It does this by abutting thefront face 41 a of the puck 28. When the blocking member 37 is retractedin response to a signal from PLC 32, and holding device 50 released,puck 28 is then frictionally engaged again by the upper surface of belt36 and will move away from station 13(iii). While being held in a fixedposition by locating and holding device 50 and or blocking member 37,the belt will continue to move and slide beneath the underneath surface41(f) of base 41 or puck 28.

The sequence of operation at station 13(iii) is as follows: PLC 32 sendsa signal that activates the blocking member 37 to extend it upward to ablocking position. This can be in response to a signal received from aproximity sensor 48 that a puck 28 is approaching the correct positionfor loading a receptacle. A proximity sensor 48 will then detect an IDmarker 43/44. When it does this, a signal is sent to PLC 32, which thensends a signal that activates the holding device 50, such that the puckis lifted upwards above belt 36 and the ridge member 806 then engagesgrooves 45 and 46 of the first puck. When holding device 50 is beingactivated, PLC 32 also sends a signal to item receptacle dispenser 16 todispense an item receptacle 22 onto the puck 28 which is being heldbelow. The next puck 28 will abut the rear surface of first puck 28. Asecond proximity sensor 48 thereafter will detect the arrival of thenext puck 28 in series, by detecting ID marker 43/44. The signalassociated with the arrival of the second puck then deactivates theblocking member 37 and activates the holding device 50 to release thefirst puck 28. With that both pucks 28 advance forward by conveyor belt36. After a certain delay, (and possibly after receiving a signal) PLC32 activates again the blocking member 37 to extend it to a blockingposition. That stops the next, second puck 28 and the whole itemreceptacle process starts again from the beginning.

With reference now to FIGS. 14 a and 14 b, an item receptacle dispenser16 is illustrated in detail in side view and perspective view. Dispenser16 comprises a plate frame generally designated 130 and a magazine 134.Magazine 134 holds a series of stacked receptacles 22 between upstandingrods 132, which holds the stack in a generally vertical orientation. Thereceptacles 22 in the stack may be in a nested arrangement. It isnecessary to separate a single receptacle 22 from the stack and depositit onto a puck 28. Because of the stacked, and also possibly the nested,arrangement of the receptacles 22, this is not easy to accomplish.However the dispenser 16 is adapted to accomplish this task.

As shown in FIGS. 14 a and 14 b, dispenser 16 includes a pneumaticcylinder 136 that has one end 136 a secured to an end portion of frame130. Cylinder 136 has a reciprocating piston arm 138 at the opposite endwhich has an end secured to a slidable block 133. Block 133 is securedto the bottom of a slidable plate member 145, which is slidable in apair of spaced rail members 135. Accordingly, by operation of cylinder136, the plate member 145 has reciprocal movement on longitudinal railmembers 135. The reciprocating movement of arm 138 caused by doubleacting cylinder 136 is controlled by PLC 32 with which it is incommunication.

Note, in FIG. 14 b, only one of the two plate members 145, cylinder 136and other components is shown, for clarity.

Frame 130 has an aperture 252 formed therein, through which is receivedthe stack of item receptacles 22.

Plate member 145 has a pair of spaced edge blades 147 a, 147 b at oneend of an opening 250 in plate member 145. A set of ramp members 137 aare directed toward the end of aperture 250 where the blades 147 a, 147b are disposed. Cavities 141 a, 141 b are provided at each end of theframe.

In use, and as shown in successive FIGS. 15 a, 15 b; 16 a, 16 b and 17a, 17 b, each of the edge blades 147 a, 147 b moving in one directionfrom when the piston 138 is retracted, will engage between side lips 22e of a first bottom receptacle and an adjacent receptacle stacked on topthereof. The blades 147 a, 147 b will strip off the bottom receptacle inthe stack and move it towards the end cavity, and it will drop thereceptacle through aperture 252 in plate number 145 onto the puck 28from the cavity 141 a.

When plate member 145 moves in the opposite direction, the ramp members137 a will engage the bottom receptacle of the remaining stack ofreceptacles 22 and tend to lift the stack back up to a position where itwill be ready again to repeat the process of having edge blades 147 a,147 b, peel the next receptacle from the bottom of the stack.

Thereafter, a mechanism can be provided which will ensure the presenceand proper placement of a receptacle 22. Such a mechanism could be acamera vision system. However this mechanism can also be a pneumaticcylinder arrangement 300 such as is shown in FIGS. 18 a and 18 b. Pistonarrangement 300 includes a frame 314, which can be mounted to part ofthe system frame 15. A double acting pneumatic cylinder 310 has one endmounted to an end portion 314 a of frame 314. The cylinder 310 has apiston arm 312, which can be extended and retracted. The outer end ofpiston arm 312 is fixed to the end of pivot arm 318. Pivot arm ismounted for rotation with a pin 322, and can rotate between the twopositions shown in FIGS. 18 a and 18 b. When operated, piston arm 312can be retracted from a first position in FIG. 18 a to a second positionshown in FIG. 18 b. This causes the end 320 of arm 318 to rotatedownwards towards the upper surface of the puck 28 that is being held atthe station. If a receptacle 22 has been loaded and is in the properposition, the piston will reach a certain position in its stroke andwill be unable to complete its full stroke downward. The result is asignal is sent to PLC 32, which signifies a receptacle has been properlyreceived on the top surface of base 41 of puck 28. The PLC 32 will thensend signals to the blocking member 37 to retract, and then to holdingdevice 50 to release the puck 28. The belt 36 will then frictionallyengage the under surface 41(f) of puck 28 and that puck will then moveforward along conveyor path 13.

Further along the conveyor path 13 is the downwardly sloped ramp portion13(iv) that provides item loading station 17 (FIG. 2). The slope ofconveyor 13 path and the corresponding belt 36 is at an angle alphawhich will be selected, dependent upon several factors including thenature of the items 20 and the receptacles 22. For items comprisingblister battery packages to be loaded into tray receptacles 22, it hasbeen found that an angle alpha in the range of about 20 to 40 degreesworks well, and that a most preferred angle for alpha is about 30degrees. The trajectory of the items 20 as they are delivered to thereceptacle will be close to perpendicular to slope of the conveyor pathand to the orientation of the upper plane of the base of puck and thereceptacles. However, as will be described later, this trajectory can bevaried by several degrees from perpendicular to the slope, and this canprovide an impact of each item 20 upon an energy absorption device toprovide for the desired energy absorption of the item 20 before it isdelivered into the slot 22 a of a receptacle 22.

Several items 20 are delivered by item delivery conveyor 14 in seriesinto an item receptacle 22 being held in a puck 28, which is at the itemloading station 17. Also at this loading station 17, as shown in FIGS. 5and 6, a mechanism is provided that moves the pucks through the stationwith indexed intermittent motion that allows for the receptacle 22 to befilled with items 20. This motion can, as illustrated, be effected byhaving a drive gear wheel 54 engage edge that provides longitudinaltooth mesh 52 on side surface 41 d of puck 28. The result is thatrotation of gear wheel 54 will cause and translate into longitudinalmovement of the mesh 52. This results in the longitudinal movement ofthe puck 28 in the same direction, as conveyor belt 36 is moving. Thegear wheel 54 can be driven for intermittent rotation resulting inintermittent longitudinal movement of puck 28 through the item loadingstation 17. The intermittent movement of puck 28 in a longitudinaldownstream direction allows successive items to be loaded into the itemreceptacle 22. The amount of rotation of the gear wheel 54 can beselected to provide for suitable longitudinal movement of the puck 28,to allow for the proper placement of successive items 20. The gear wheel54 can be driven by a servo-drive motor such as model NTM-207-CBNS-0000manufactured by EMERSON. The operation of the drive motor for gear wheel54 can be controlled by PLC 32.

It is preferred that the spacing of the slots in the item receptacles 22is directly related to the number and spacing of the teeth on the gearwheel 54/mesh 52. The spacing relates to gear rotation as 360/2.25π degto 1 inch of spacing.

It is preferred that more than one puck 22 be at the item loadingstation 17 at the same time. This is so that while one puck is beingloaded, the next puck in series has its front face abutting the rearface of the leading puck. This enables the gearing system to moveseamlessly from loading one puck to loading the next puck (i.e. there isno break in the engagement of teeth of the gear wheel 54 between themesh of one puck to the mesh of the next puck). The relative position ofthe gear wheel 54 relative to the pucks is continually maintained,without the system having to re-set or re-calibrate every time aftereach puck has been loaded to the item loading station 17.

When a puck 28 arrives at item loading station 17, the puck will be inabutment with another puck 28 that is in front of it. Once the leadingpuck is loaded, it will become disengaged from the gear wheel 54. Whileeach puck 28 is moved down the sloped ramp through the item loadingstation 15, controlled by the movement of gear wheel 54 engaging mesh52, the conveyor belt 36 will independently continue to slide forwardrelative to the puck 28. This motion will be executed until a proximityswitch 48 (at 13(iv) sees mark 44. It is only when the mesh 52 becomesdisengaged from the gear wheel 54, that the belt 36 will frictionallyre-engage the base of the puck and move that puck down the rest of theramp portion 13(iv) and onto horizontal conveyor path portion 13(v) atthe same speed as the belt 36. It will be noted that the frictionalinteraction may be selected such the frictional force acts against theforce of gravity acting on the puck tending to push the puck down theramp. The frictional force will thus prevent the puck sliding down theslope, but instead will move with belt 36.

Also to assist in loading items 20 into the receptacle 22, a positioningassembly generally designated 56 can be provided as shown in FIGS. 2 a,5, 6 and 7. In this embodiment, assembly 56 mounted (in a manner notexplicitly shown) to part of the system frame 15. Assembly 56 includes abase plate 58 and a top plate 62 interconnected by a block member 63. Asshown in FIG. 7, base 58 has an extension portion 59, which providesenergy dissipation for items 20, which strike an outer end of extension59. Extension portion 59 may simply be made from a metal such as steel.Alternatively, it may have positioned on an upper surface thereof amaterial such as rubber, with suitable energy absorption properties.When an item 20 strikes the end of extension 59, a significant amount ofits energy will be dissipated.

Assembly 56 also includes a resilient spring plate 64 affixed proximateone end to the underside surface of top plate 62. A spring cantileversupport member 67 is provided and has an end portion 67 a, whichcontacts a rear surface of spring plate 67. Spring plate can forexample, be made from a thin strip, such as for example 28 gauge ofsteel or other suitable resilient material. Other force exertingmechanisms to move the items longitudinally so the items slide into thenext open slot 22 a, could also be employed such as ultra high molecularweight polyurethane.

Also at item loading station 17, is an item-loading chute 80. Items 20being fed from item feed conveyor 14 are fed onto chute 80 (as describedin detail below), and then fall down the top surface of chute 80.

With reference to FIGS. 7, 9 a and 9 b it will be seen that the incomingtrajectory of an item 20 can vary from being perpendicular to the slopeof conveyor path 13. However, the trajectory, could be substantiallyperpendicular in some embodiments. However, in this embodiment, thetrajectory is such that items 20 will exit the chute 80 and the lowerpart of the blister portion 20 a will impinge against and resilientlydisplace a lower portion of spring plate 62. The trajectory is such thatat least a portion of the lower face 20 d of portion 20 a will firstdisplace the spring plate 62 and then impact on the end of plateextension 59. The result is that although the item 20 will reboundupwards a small amount after striking against the end of plate extension59, most of its energy is dissipated. After the impact, item 20 will bepushed by spring plate 62 towards the previously loaded item 20 held inthe receptacle, and will be guided into its own respective slot 22 a inthe receptacle, in part by the previously loaded item. It may beappreciated that without this energy dissipation mechanism and springmechanism, if it was attempted to feed the item directly into the slot22 a, the item 20 might bounce out and may not be easily received intothe slot.

It should be noted that the first item loaded into each receptacle 22will be guided in part by rear arms 406 of the puck 28 (not shown inFIG. 7, but shown in FIGS. 8 a-8 c).

In some embodiments a spring mechanism alone may provide sufficientguidance to feed an item 20 which bounced out of a slot 22 a, back intothe slot 22 a.

Other energy dissipation mechanisms could be employed such as providinga magnet mounted under top surface of extension portion 59, which mightexert a magnetic attractive force on a suitable item.

While the disclosed embodiment contemplates using gravity to assist indirecting the item down a chute and into a slot 20 a, in otherembodiments the items may be propelled toward a slot by othermechanisms.

Returning to FIG. 7, a proximity sensor 49 is also employed in thevicinity of loading station 17. Sensor 49 may be a model VS2KAPSVQmanufactured by BANNER and will detect the movement of an item 20 pastit in the vicinity of the chute, preferably the lower portion to thechute 80. Proximity sensor 49 is adapted to send a signal to PLC 32 inresponse to the detection of an item. In response to the signal, PLC 32causes the gearing wheel 54 to be rotated to index the puck 28 forward,once sufficient time has elapsed for the last item loaded to be receivedin the slot 22 a. The next slot is then properly positioned to await thenext item being fed by item feed conveyor 14.

Turning now to item delivery conveyor system 14, this conveyor system isshown schematically in FIGS. 2 and 2 a. Item delivery conveyor system 14includes a first stage item in-feed conveyor 24, a metering device 18and a second stage item delivery conveyor 26. Items 20 are fed randomlyon conveyor 24 to the metering device 18. Metering device 18 in theillustrated embodiment is a star-wheel 154 (illustrated in detail inFIGS. 10-13), and has a plurality of fingers 176 extending from acentral wheel comprised of inner disc 160 and outer disc 158, asdescribed below. The distance X between the end portions of consecutivefingers 176 can be chosen so that one item 20 will just fit therebetween. The conveyor 24 can be set to operate within a fairly widerange of speeds with items 20 at a variable and even random pitch.However, the speed and item pitch are generally selected so that therewill always be an adequate supply of items 20 being fed to meteringdevice 18, and that an average delivery rate over a period of time willbe at least enough to keep the metering device 18 supplied with items.

Metering device 18 is controlled by PLC 32 and when activated willrotate a sufficient amount to release item to move forward again onconveyor 24. With 23 finger members 176 (12 arcuate gaps betweenfingers) the fingers will normally be equally spaced radially at 30degrees apart. When PLC 32 sends a signal to meter device 18, themetering device drive motor will rotate the wheel, 30 degrees, whichwill cause one item 20 to be released to conveyor 26.

Second conveyor 26 is also a belt conveyor with a belt 86 but includes aseries of upstanding lugs 88 mounted thereon. Lugs 88 can be set at aspecific, constant pitch on belt 86. Conveyor belt 86 is drivenconventionally at a speed that is less than belt 31 of conveyor 24. Alsothe timing of release of an item from metering device 18 is such thatthe faster moving belt 31 will move an item and ensure that it is inabutment with the rear of a lug 88 on belt 86. The movement of belt 86can be driven by a drive motor 102, which is interconnected with a belt101 that is tied to an encoder 100. Encoder 100 sends pulsed signals toPLC 32 based on its rotational position. In this way, PLC 32 is aware ofthe specific position of belt 86 and the lugs 88 contained thereon.Thus, as PLC 32 knows the position of the lugs 88, when a lug is at anappropriate position, it can send a corresponding signal to operate themetering device 18 to release an item 20 at the correct time, so thatthe item 20 will reach a lug 88 in a proper position.

Once on conveyor belt 86, the item 20 is carried toward the entry tochute 80. During this movement of item 20 on belt 86, a camera visionsystem 90 is triggered at a particular position by PLC 32 to take adigital photo of the upward facing surface of the item 20. The camerasystem could be a model DVT530 made by BANNER which includes imagerecognition capability. The image recognition is done by the camera'sown controller and it provides to the PLC 32 only information of whethera particular image passed or failed. The image taken by the camerasystem 90 is then processed. The result of this image processing mayenable the system/PLC 32 to determine several criteria such as forexample (a) whether there an item there at all; (b) whether the item inthe right orientation; (c) whether the product(s) such as batteries heldin a transparent blister package are in the right orientation; (d)whether there are any product(s) missing in the blister package; (e)special coupon present. If as a result of the image processing, theimage does not meet the specified criteria, the PLC 32 will carry out areject operation on that item to be rejected.

To facilitate rejection of items that do not meet the specifiedcriteria, an item reject chute 120 is provided. With reference to FIGS.4, 4 a and 4 b, items 20 will fall into a reject chute 120 through a gapcreated by the rotational movement of an upper portion 80 b of feedchute 80. Upper chute portion 80 b, is pivoted clockwise (see FIGS. 4 aand 4 b) to provide a gap through which a rejected item will fall. Therotation of chute portion 80 b is facilitated by a pneumatic cylinder122 having a piston arm 126, interconnected to an arm member 128 thatcan pivot about a pin 124. Arm 128 is interconnected to the upper chuteportion 80 b.

When an item is identified as being a reject, PLC 32 sends a signal thatactivates cylinder 122 causing piston 126 to retract. This movementcauses arm 128 to rotate clockwise around pivot 124, which in turncauses upper chute portion 80 b to rotate clockwise, opening up a gap.When the reject item reaches the end of conveyor belt 86 it will fallthrough the gap into reject chute 120.

With reference to FIG. 6, metering device 18 includes a wheel membergenerally designated 154 mounted to a frame 152 with a height adjustmentmechanism 150. By rotation of a handle 156, the height adjustmentmechanism 150 can be operated to adjust the height of the wheel 154relative to conveyor 24 and items 20 carried thereon.

With reference to FIGS. 10 and 11, wheel 154 includes an outer discmember 158 and an inner disc 160, which are bolted together and do notmove relative to each other. A hub member 195 that may be integrallyformed at an outer surface of disc 160 is adapted to be mounted to ashaft connected to a drive motor (not shown). The drive motor, which maybe a servo drive motor, is controlled by PLC 32. Thus, discs 158 and 160can be rotated intermittently about the drive axis provided by the driveshaft.

Discs 158 and 160 are configured such that an inner cavity 165 isprovided and defined by the inner surfaces of the discs. Within thecavity 165, a circumferentially recessed portion 161 is provided in disc158. A middle disc 801 sits inside the recessed portion 161 and is heldtherein between the outer and inner discs 158 and 160. The configurationis such that middle disc 801 can rotate around a middle axis common withthe drive axis of rotation of discs 158 and 160 within recess 161. Block170 is bolted to bolt holes 189 in middle disc 801 through slot 168.Thus block 170 can rotate around the central axis as middle disc 801rotates around the same axis. Handle locks 162 are used to lock middledisc 801 in desired position relative to the discs 158, 160.

Block 170 rests against an outer surface of inner disc 160 but can sliderelative thereto. Block 170 has an arrow tip 172, which points to aposition on a ruler 174. Ruler 174 is calibrated to indicate theseparation distance between adjacent finger members 176 on wheel 154, aswill be described further hereafter. If block 170 is rotated in slot 168relative to discs 158, 160, then the position of tip 172 will move alongruler 174. The position of tip 172 can be selected to provide a desiredspacing of finger members 176. Finger members 176 are generally spacedequally, in this embodiment at about 30 degree intervals, around thewheel 154.

As shown in FIGS. 10-13 b, each finger member 176 includes a radiallyextending rod member 180 that is housed and held within a radiallyextending sleeve 182. Each sleeve 182 is mounted for radial movementwith rod member 180 within a radially extending slot 178 in outer disc158. At the outward end of each rod 180 is a transverse wedge shaped bar184 which is suitably configured to be able to block an end of an item20 located on conveyor 24. Thus an item 20 can be held snugly betweentwo finger members 176. When the wheel 154 is rotated, a single item 20held between two finger members can be pushed downstream.

As shown in FIGS. 12 and 13, at the inner end of each sleeve 182 is apin member 188 which is retained in the cavity provided by discs 158 and160. Each pin 188 extends outward towards a surface 801 a of middle disc801 and is received into a cam track or channel 190 machined intosurface 801 a middle disc 801. Track 190 may also be formed in otherways such as by guide side rails, which hold the pin member 188. Pinmember 188 acts as a cam follower and it will be apparent that as middledisc 801 is rotated from the position shown in FIG. 12 a, clockwiserelative to outer disc 158, the cam follower 188 moves along the camtrack to the position shown in FIG. 12 b. The result is that each rod180/sleeve 182 of each finger member 176 will retract in its respectivesleeve 182, and the spacing X between adjacent fingers will be reducedfrom X1 to X2.

By rotating the middle disc 801 in the opposite direction relative toouter disc 158, the pins 188 will move in the opposite direction in thecam track 190, which will cause the finger members 176 to expand. Thedistance X between finger members 176 can thus be selected dependingupon the length of the items 20 on conveyor 24.

The general operation of the sub-system 10 is as follows. Pucks 28, withneither a receptacle 22 nor any items 20, move in series up generallyupwardly sloped ramp portion 13(i) on conveyor 12 assisted by conveyor23. The pucks 28 then move along generally horizontal upper section13(ii) to conveyor portion 13(iii), which provides the item receptacleloading station. At this station, the holding mechanism described aboveis initiated by PLC 32, and a puck 28 is held by holding device 50. PLC32 also then sends a signal to dispenser 16 causing dispenser 16 to loada receptacle into puck 28 such that it will lie substantially flat onthe base of the puck 28. Once the item receptacle 22 is loaded, thereceptacle checking mechanism can check the receptacle 22 is properlyplaced in the puck 28, and if a receptacle is properly seated, anappropriate signal is sent to PLC 32. If not, another signal is send toPLC 32 providing an alarm.

This will cause the system to shut down so the problem can be corrected.However, if a receptacle 22 is properly situated on a puck 28, thecorresponding signal causes PLC 32 to send a signal to holding mechanism50 such that the puck 28 is released by holding mechanism 50. The puck28 then moves to, and starts to travel down, downwardly sloped rampportion 13(iv) to item loading station 17. Once the puck reaches station17, will abut another puck 28 already being loaded by the item loadingapparatus. Once the previous puck is loaded, the gear wheel 54 willseamlessly disengage from the previous puck and the mesh 52 of the newpuck 28 will be engaged by the teeth of gear wheel 54. The puck 28 willthen be moved intermittently through the loading sequence. Theintermittent longitudinal movement of the puck 28 will correspond to theintermittent rotation of the gear wheel 54, which is controlled by PLC32. The intermittent movement of the puck 28 will be controlled by PLC32, which receives signals from the proximity sensing devices detectingthe presence of ID markers 43 and 44, and from the proximity sensor 49.It will be recalled that sensor 49 is adapted to send a signal to PLC 32in response to the detection of an item passing down the chute 80 to beloaded into the receptacle held in a puck 28 at loading station 17. Asdescribed above, items 20 are fed to loading station 17 by conveyorsystem 14.

After being fully loaded with items 20 into the receptacle 22, the puckwill be released and will move down the ramp portion 13(iv) the pucks 28under the control of belt 36, and then travel along a generallyhorizontal lower section 13(v) to an item unloading station 13(vi). Atitem loading station 17, the receptacle 22 is removed from puck 28 withrobot device 34. This could be done “on the fly” but is preferably doneby holding the puck 28 still using a holding device which can be likethe holding device 50 employed at the item receptacle loading station.After item unloading station, the pucks 28, then move again to upwardlysloped ramp portion 13(i) and repeat thereafter the process.

1. A system for loading a plurality of items in series into a receptacleheld in an item holding device, comprising: (a) a plurality of itemholding devices each adapted for holding an item receptacle, each itemreceptacle being adapted to receive and hold a plurality of items; (b) aholding device moving apparatus for moving said plurality of itemholding devices to and through an item loading station with said itemreceptacles being oriented at a first angle to the horizontal duringloading of a plurality of items; (c) an item delivery apparatusdelivering to an item loading station, a plurality of items separatelyin series at an item orientation that is at a second angle to said itemreceptacles when each item receptacle is at said item loading station,said item delivery apparatus directing items towards each itemreceptacle in turn held in a holding device at said item orientation;wherein said holding device moving apparatus comprises: (a) an itemholding device conveyor having a conveyor path for moving said pluralityof holding devices to an item loading station; (b) an indexingintermittent movement apparatus for moving each of said plurality ofitem holding devices at said first angle with indexed intermittentmovement to allow said plurality of items to be loaded sequentially intoeach said item receptacle; and wherein each item of said plurality ofitems is delivered in series by said item delivery apparatus towardseach item receptacle held in a holding device, and each said holdingdevice is moved with indexed intermittent movement through said itemloading station to permit a plurality of items to be sequentially loadedinto each said item receptacle.
 2. A system as claimed in claim 1wherein said item holding devices and said item receptacles are bothoriented at said first angle to the horizontal.
 3. A system as claimedin claim 2 wherein said first angle is in the range of about between 20to 40 degrees to horizontal.
 4. A system as claimed in claim 3 whereinsaid second angle is about 90 degrees.
 5. A system as claimed in claim 2further comprising an energy absorption member, positioned to beimpacted by said items discharged toward said item holding device.
 6. Asystem as claimed in claim 2 wherein each of said item holding devicescomprises a puck movable along said conveyor path.
 7. A system asclaimed in claim 6 further comprising an item receptacle loading stationat which said item receptacle is loaded into said puck, prior to movingalong said conveyor path to said item loading station.
 8. A system asclaimed in claim 2 wherein said item delivery apparatus comprises aninput conveyor delivering items in series to a metering device, saidmetering device dispensing items to an output conveyor that feeds saiditems to a guide mechanism that directs items towards said holdingdevice at said item orientation.
 9. A system as claimed in claim 8further comprising an item receptacle dispenser disposed upstream fromsaid item loading station, said item receptacle dispenser having amagazine containing a plurality of item receptacles, said itemreceptacle dispenser adapted for dispensing an item receptaclesuccessively into each item holding device and wherein said holdingdevice moving apparatus is operable to move said plurality of itemholding devices to and through a receptacle loading station at whichsaid item receptacles are loaded into said item holding devices by saiditem receptacle dispenser, prior to moving said item holding devices tosaid item loading station.
 10. A system as claimed in claim 8 whereinsaid metering device comprises a wheel member having a plurality ofgenerally radially extending, generally equally spaced finger members,with all adjacent finger members being configured at a distance therebetween proximate end portions of said adjacent finger members, forholding at least one item there between.
 11. A system as claimed inclaim 10 wherein said fingers are radially adjustable in order to varysaid distance between end portions of adjacent fingers.
 12. A system asclaimed in claim 10 wherein said wheel member comprises a first membermounted for rotation relative to a second member, said first memberhaving a plurality of cam tracks associated therewith, said secondmember configured to support said finger members for adjustable radialmovement, said finger members each having associated therewith a camfollower which is received in one of said cam track of said firstmember, such that rotation of said first member relative to said secondmember, causes an adjustment in the radial extension of each said fingermember, to vary said distance.
 13. A system as claimed in claim 1wherein said indexing intermittent movement apparatus comprises arotatable gear wheel, having teeth adapted for engaging a longitudinallyextending gear mesh on said item holding device, such that rotation ofsaid gear wheel is translated into longitudinal movement of said itemholding device, the movement of said gear wheel being controlled by acontrol device.
 14. A system as claimed in claim 1 wherein said an itemdelivery apparatus comprises a chute oriented substantially at said itemorientation to guide said items towards said item holding deviceslocated at said item loading station.
 15. A system as claimed in claim14 further comprising an energy absorption member, positioned to beimpacted by said items discharged from said chute toward said itemholding devices located at said item loading station.
 16. A system asclaimed in claim 15 further comprising a resilient spring member, saidspring member movable from (a) a resting position to (b) a displacedposition when impacted by an item discharged from said chute toward saiditem holding device to (c) a item loading position wherein said springmoves said item to a position where it can be more readily be receivedby said item holding device.
 17. A system as claimed in claim 16 whereinan item is guided into said item receptacle with the assistance of apreviously loaded item in said item receptacle.
 18. A system as claimedin claim 1 further comprising an energy absorption member, positioned tobe impacted by said items discharged toward said item holding device.19. A system as claimed in claim 1 wherein said item receptacle is atray receptacle having a plurality of spaced transverse slots, andwherein each of said items has a lower edge portion receivable in saidslots.
 20. A system as claimed in claim 19 wherein said items areblister packages containing at least one product.
 21. A system asclaimed in claim 1 wherein said item receptacle is a tray receptaclehaving a plurality of spaced transverse slots, and wherein said itemshave a lower edge portion receivable in said slots.
 22. A system asclaimed in claim 12 wherein said items are blister packages containingat least one product.
 23. A system as claimed in claim 1 furthercomprising a resilient spring member, said spring member movable from(a) resting position to (b) a displaced position when impacted by anitem discharged toward said item holding device to (c) a item loadingposition wherein said spring moves said item to a position where it canbe more readily be received by said item holding device.
 24. A system asclaimed in claim 1 wherein an item is guided into said item receptaclewith the assistance of a previously loaded item already loaded into saiditem receptacle.
 25. A system as claimed in claim 1 wherein said itemdelivery apparatus further comprises an input apparatus, a wheel memberand an output apparatus, said wheel member having a plurality ofgenerally radially extending, generally equally spaced, finger members,with all adjacent finger members being configured at a distance therebetween proximate end portions of said adjacent finger members, forholding at least one item there between.
 26. A system as claimed inclaim 25 wherein said fingers are radially adjustable in order to varysaid distance between end portions of adjacent fingers.
 27. A system asclaimed in claim 25 wherein said wheel member comprises a first membermounted for rotation relative to a second member, said first memberhaving a plurality of cam tracks associated therewith, said secondmember configured to support said finger members for adjustable radialmovement, said finger members each having associated therewith a camfollower received in one of said cam tracks, such that rotation of saidfirst member relative to said second member, causes an adjustment in theextension of each said finger member, to vary said distance.
 28. Asystem as claimed in 25 wherein said wheel member is rotatably driven bya motor for intermittent rotation movement.
 29. A system as claimed inclaim 28 wherein said motor is controlled by a controller device.
 30. Asystem for loading a plurality of items in series into an itemreceptacle held in an item holding device, said system comprising: (a) aplurality of item holding devices each adapted for holding an itemreceptacle adapted to receive and hold a plurality of items; (b) aholding device moving apparatus for moving said plurality of itemholding devices through an item loading station with said itemreceptacles; (c) an item delivery apparatus delivering a plurality ofitems to said item loading station, said item delivery apparatusdelivering a plurality of items in series towards an item holding deviceof said plurality of item holding devices; (d) an energy absorptionmember being separated from said plurality of item holding devices, saidenergy absorption member being positioned to be impacted by said itemsdelivered toward said item holding device when positioned at said itemloading station and said energy absorption member being positionedopposite to a loaded item when a loaded item is held in the itemreceptacle; wherein each item is delivered by said item deliveryapparatus toward said item holding device in such a manner that itimpacts said energy absorption member which assists in loading said itemreceptacle with each item, and wherein after impacting said energyabsorption member, at least one item is guided between a previouslyloaded item held in the receptacle and the enemy absorption member, andinto said item receptacle.
 31. A system as claimed in claim 30 furthercomprising a resilient spring member, said spring member movable from(a) a resting position to (b) a displaced position when impacted by anitem discharged by said item delivery apparatus toward said item holdingdevice to (c) a item loading position wherein said spring moves saiditem to a position where it can be more readily be received by said itemholding device.
 32. A system for loading a plurality of items in seriesinto a receptacle held in an item holding device, said systemcomprising: (a) a plurality of item holding devices each adapted forholding an item receptacle adapted to receive and hold at least oneitem; (b) a holding device moving apparatus for moving said plurality ofitem holding devices to and through an item loading station with saiditem receptacles; (c) an item delivery apparatus delivering a pluralityof items in series to said item loading station, said item deliveryapparatus directing items towards an item holding device located at saidloading station; (d) a resilient spring member, said spring membermovable from (a) a resting position to (b) a displaced position whenimpacted by an item discharged by said item delivery apparatus towardsaid item holding device to (c) a item loading position wherein saidspring moves said item to a position where it can be more readily bereceived by said item holding device; wherein each item is delivered bysaid item delivery apparatus toward said holding device in such a mannerthat it impacts said spring member which assists in loading saidreceptacle with said item.
 33. A system for loading a plurality of itemsin series into a receptacle held in a puck, comprising: (a) a pluralityof pucks each adapted for holding an item receptacle adapted to receiveand hold a plurality of items, each of said plurality of pucks having asurface for frictionally engaging a surface of a drive belt conveyor;(b) a continuous drive belt conveyor for frictionally engaging saidsurface of each of said plurality of pucks to move said plurality ofpucks in series to an item loading station; (c) a movement apparatus atsaid item loading station adapted for receiving pucks from said beltconveyor, said movement apparatus adapted for co-operation with each ofsaid pucks in series to provide for movement by engagement of at leastone protrusion in at least one slot, thereby moving each of said puckswith intermittent movement through said item loading station with saiditem receptacles being oriented at a first angle to the horizontal; (d)an item delivery apparatus delivering to an item loading station, aplurality of items in series at an item orientation that is at a secondangle to said item receptacles when each receptacle is at said itemloading station, said item delivery apparatus directing items towardseach receptacle in turn held in a puck at said item orientation; whereineach item of said plurality of items is delivered in series by said itemdelivery apparatus towards each receptacle held in a puck, and each saidpuck is moved through said item loading station to permit a plurality ofitems to be loaded into each said receptacle.
 34. A system as claimed inclaim 2 wherein said at least one protrusion and at least one slotcomprise a gear mechanism that comprises a gear wheel and a meshlongitudinally oriented on each said puck.
 35. A system for loading aplurality of items in series into a receptacle held in an item holdingdevice, comprising: (a) a plurality of item holding devices each adaptedfor holding an item receptacle, each item receptacle being adapted to beloaded with a plurality of items; (b) a holding device moving apparatusfor moving said plurality of item holding devices through an itemloading station with said item receptacles being oriented at a firstangle to the horizontal during loading of a plurality of items; (c) anitem delivery apparatus delivering a plurality of items separately inseries at an item orientation that is at a second angle to said itemreceptacles when each item receptacle is being loaded, said itemdelivery apparatus delivering a plurality of items to item receptaclesas said item holding device is held in a holding device at said itemorientation; wherein said holding device moving apparatus comprises anindexing intermittent movement apparatus for moving each of saidplurality of item holding devices at said first angle with indexedintermittent movement to allow said plurality of items to be loadedsequentially into each said item receptacle; and wherein a plurality ofitems is delivered in series by said item delivery apparatus to eachitem receptacle held in a holding device, and each said holding deviceis moved with indexed intermittent movement through said item loadingstation to permit a plurality of items to be sequentially loaded intoeach said item receptacle.
 36. A system as claimed in claim 35 whereinsaid first angle is in the range of about between 20 to 40 degrees tohorizontal.